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Thank you for purchasing a Sinister Manufacturing Company EGR delete kit. Precision manufactured using aircraft quality 304 stainless steel and billet aluminum; this EGR kit is designed to endure years of heavy use. Installing a Sinister EGR kit with up-pipe on your vehicle will eliminate the restrictive design of the stock up pipe, allowing your turbo to get more air while preventingcoolant from leaking into the intake. The result is a slight gain in horsepower and longer engine life.These installation instructions have been written to help you in the installation of your SinisterEGR kit. Please read it completely before installing your kit.

This Kit has been designed for:2003-2007 Ford F250/350/ crew cab, long bed, short bed, and Excursion equipped with a 6.0L V8 Power stroke turbo diesel engine and automatic or manual transmissions

This kit may void factory warranty please check with manufacturer.

This kit is intended for off-road use only.

Sinister Manufacturing Company recommends that a diesel shop or professional after market parts installer,who has all the necessary equipment, tools and experienced personnel needed for proper installation,should perform the installation of this system. However, if you decide to perform the installation, werecommend someone should help you. Ensure the installer uses all under car safety precautions includingeye protection.

Please take time to read and understand the following…By installing your Sinister EGR kit , you indicate that you have read this document and you agree with the terms stated below. It is the responsibility of the purchaser to follow all installation instruction guidelines and safety procedures supplied with your Sinister EGR kit.

Sinister Manufacturing Comany assumes no responsibility for damages occurring from misuse, abuse,improper installation, improper operation, lack of responsible care, or all previously stated reasons resultingfrom incompatibility with other manufacturer’s products and/or systems.

Included with your Sinister EGR kit is a warranty card. Please read it carefully before you begin any work on your vehicle. If you should have any questions regarding our warranty policy, installation, or any other matter pertaining to your new Sinister EGR kit, please give us a call at the number provided on the warranty card.

Please call us at 877-692-4110 Mon-Fri 8am-5pm if you need any additional assistance.

Copyright c 2008 Sinister Mfg. Company 2025 Opportunity Drive Ste 7, Roseville, CA 95678

Basic 6.0L EGR Delete KitBasic 6.0L EGR Delete KitR

PACKING LIST:

QTY. DESCRIPTION21111

Worm Drive Hose Clamp3/4” Silicone HoseBillet EGR Cooler Block-Off with O-ring and 180 Degree Stainless Steel Coolant TubeUp-pipe bolock-off disk

Sinister Mfg. Company Diesel EGR bill of materialsSinister Mfg. Company Diesel EGR bill of materials

Caution!!! Never work on a hot exhaust system. Serious injury in the form of burns can result If thevehicle has been in use and the exhaust system is hot, allow vehicle to cool for at least 1 hour. Always weareye protection when working under any vehicle.

Note: It is our recommendation that you use a hoist or hydraulic lift to facilitate the installation of yournew Sinister EGR Delete Kit (for exhaust removal).

Note: Before removing the original parts from your vehicle, please compare the parts you havereceived with the bill of materials provided on this page to assure that you have all the partsnecessary for the installation of your new Sinister EGR kit.

Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaustfasteners and allowing a significant period of time for the chemical to lubricate the threads beforeattempting to disassemble.

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Original EGR System RemovalOriginal EGR System Removal

Figure 1.0Figure 1.0

Step 1: Disconnect BatteriesStep 2: Drain coolantStep 3: Remove clips for plastic wire way located above turbo. Fold to windshield of truck. figure 1.0

Step 4: Remove upper fan shroud by prying away from radiator through slots figure 2.0/2.1

Figure 2.0Figure 2.0 Figure 2.1Figure 2.1

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Step 6: L Unbolt alternator and disconnect wiresfigure 4.1, then tilt towards front of vehicle. Note: it is not necessary to loosen belt tensioner.

oosen clamps and remove charge pipe figure 4.0.

Step 5: Loosen hose clamps and remove intake tube figure 3.0. Then unscrew bolts and remove turbo inlet tube and PCV Valve figure 3.1

Step 7: Disconnect downpipe by removing v-clamp from back of turbo figure 5.0 and remove the 2 bolts from the catalytic converter figure 5.1.

Figure 4.0Figure 4.0 Figure 4.1Figure 4.1

Figure 3.0Figure 3.0 Figure 3.1Figure 3.1

Figure 5.0Figure 5.0 Figure 5.1Figure 5.1

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Step 8: Remove turbo charger. This is done by removing the two oil feed line bolts, VGT actuatorwire, Up-pipe v band clamp, and the three turbo mounting bolts. It is strongly recommended to use penetrating oil on all turbo bolts, exhaust up pipe bolts, and pedestal bolts. Once these parts are removed the turbo will roll toward the passenger side of the truck and out of the pedestal. Figure 6.0

Step 9: Remove the turbo mounting pedestal, Remove the oil drain tube from the H.P.O.P cover figure 6.1

Figure 6.0Figure 6.0 Figure 6.1Figure 6.1

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Step 10:

figure 7.0

Loosen do not remove the intake manifold bolts on the drivers side. Completely remove the intake manifold bolts from the passenger side and note their location using a piece of cardboard

Remove the two bolts that go through the inner fan stator (located under the shroud) 7.1

Figure 7.0Figure 7.0 Figure 7.1Figure 7.1

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Step 11: Remove the bolt that is used to stiffen the heater tube to the manifold (located below alternator). Bend this tab upward figure 8.0

Step 12: Remove EGR cooler mounting bolts (3 total) figure 8.1

Step 13: Lightly push down on the EGR cooler while pulling up on the intake manifold to disengagefrom the manifold figure 9.0

Step 14: While holding the manifold up with a small pry bar move the cooler toward the back of the engine. Continuing to hold the manifold up, lift and remove the cooler through the front of the engine. Be sure that all gaskets and o-rings are removed with the cooler figure 9.1

Step 15: Install supplied EGR cooler block off disk to up-pipe using existing v-clamp.

Step 16: Replace intake manifold bolts and torque to 120inlbs

Figure 9.0Figure 9.0 Figure 9.1Figure 9.1

Figure 8.0Figure 8.0 Figure 8.1Figure 8.1

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Step 17: Install the 3/4” silicone hose, 3/4” 180 degree Stainless steel coolant tube provided, and the worm drive hose clamp rings loose on the hose

Step 18: Grease the Sinister billet adapter o-ring. Place into intake manifold bore. Finger tighten the two longer factory cooler mounting bolts. The third smaller bolt can be discarded figure 10.0

Step 19: Tighten billet adapter bolts to 120inlbs, while tightening make sure the o-ring stays in place and alignment is correct. Be sure not to over torque the bolts. Slide hose over the oil cooler nipple and tighten both hose clamps figure 10.1

Step 20: Reinstall turbo, all intake and exhaust tubes including down pipe, alternator, shroud, wires etc.in reverse order from steps 3 to 17

Step 21: Refill with new coolant, use manufacturer recommended and mix according to label

Step 22: You are ready to test the Sinister delete kit. Start engine and run till coolant circulates. Top off coolant system if needed. Make a close inspection for any coolant leaks or oil leaks.

Figure 10.0Figure 10.0 Figure 10.1Figure 10.1